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Old 03-07-2010, 06:46 PM
Chuckster Chuckster is offline
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Default Cross threaded spark plug

I decided to change the plugs on my 2003 4.0 and wehn I removed the #6 plug it was hard to get out because the previous owner cross threaded it in the hole. I do have some good threads on the bottom end of the hole and I was wondering if anyone has used a "BACK TAP" tool on a problem like this with good results. Any tips would be appreciated.
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Old 03-07-2010, 07:00 PM
joeynm22 joeynm22 is offline
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Default Re: Cross threaded spark plug

Try coating the back tap tool with a vary small amount of grease. This will allow any metal pieces from the damaged threads to stick to the tool, and not fall into the cylinder during this process. Once you've threaded the back tap all the way in. Expand the tool, and thread it out. You should hopefully (keep ur fingers crossed) have a new set of good working threads. If that doesn't work you might need a thread insert. Good luck!
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Old 03-07-2010, 10:03 PM
West West is offline
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Default Re: Cross threaded spark plug

I have used one in the past. Worked great. And make sure you do what joeynm22 said and put some grease on it to catch the metal shavings.

If it fails though, you could use heli-coils. I have never used them or know exactly how they work, but have heard good things about them.
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Old 03-27-2010, 02:13 PM
texasccl2 texasccl2 is offline
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Default Re: Cross threaded spark plug

it is probably too late for this post but make sure you use the silver colored (permatex or locktite brand, etc. ) antiseize compound or paste to coat the sparkplug threads prior to installing them in the head. your plug threads will not seize in the head and will make for an easier removal next time. in about 100,000 miles or so.
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  #5  
Old 03-28-2010, 01:46 PM
4.0fan 4.0fan is offline
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Default Re: Cross threaded spark plug

heli coils are the way to go when that happens
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  #6  
Old 03-30-2010, 07:26 AM
Chuckster Chuckster is offline
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Default Re: Cross threaded spark plug

Heli Coils are great and work well, BUT..... I would never use a "spring type" heli coil on a installed head because "IF" you were to break off the stainless steel insert tang (must be removed after installing) you may drop/loose it in the cylinder and then you would have to pull the head if you do not fish it out with a grease coated dowel. Best solution is to use the threaded insert (bushing style) made by Heli Coil that does not have the "installation tang" on it. These insert kits are inexpensive and easy to use without drilling.
If the head is removed I would use the stainless Heli Coils because they are the best way to repair threads.
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